Floor height gauge

ABSTRACT

A floor height gauge for setting concrete floors is provided. The floor height gauge for setting concrete floors comprises a body, flange, knob and a possible string notch, as well as it can be used in conjunction with a protrusion or stake, insuring accuracy and eliminating the necessity for skilled workers when setting slab top elevations of concrete slabs. The floor height gauge provides a rotational means for one concrete worker to rotate a screed to level concrete to a slab top elevation.

RELATED APPLICATIONS

The Present application claims priority to U.S. Application No. 62/924,821, filed Oct. 23, 2019 and U.S. Provisional Application No. 69/924,810, filed Oct. 23, 2019 which are incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

The present application relates to methods and systems for setting a reference height or elevation, for example, for construction projects. More specifically, the present application provides a system for setting the height or elevation around pipes and other protrusions through the ground or concrete slabs.

Whether building a home or commercial structure, placing the concrete slab changes the direction of construction efforts. Before the slab is finished, the work crew is typically installing underground utilities, grading the site, preparing footings, waterproofing, installing reinforcing wire or rebar and generally working on a horizontal plane. Most construction does not really begin to move upward until after these steps are completed.

The next step, upward, begins with placing the concrete slab. This is primarily occurring with the setting of elevations and screed of the concrete. Typically, the plan for this step is left up to the contractor. The plan or method used varies from contractor to contractor. Knowledge of this process is generally concrete worker trade knowledge passed along from master to apprentice. The objectives to be met, at this step, are to set the surface of the concrete at a certain elevation, to keep the concrete flat or at a required slope. A variety of tools are used including grade stakes, forms, levels, and screeds, etc., which although not complicated to use require additional effort and time to realize the benefits thereof.

Generally, concrete placement begins at one corner and proceeds in parallel sections along grade or screed lines the contractor has established using a laser level, setting the top of forms and pen or paint marking plumbing pipes and conduit protrusions, along their side, through the established grade elevation. Concrete workers continue throughout the pour to keep the concrete reinforcement in the proper position and do finish work to keep the concrete level, with hand tools, around plumbing pipes and conduits protruding through the top of the established floor elevation.

Typically, after the concrete is screeded workers bull float the concrete and add concrete in any low areas. Hand floats are used to work the edges of the slab to make sure the perimeter of the slab is flat and smooth as well as areas around where plumbing pipes and conduits protrude through the floor. Next, the concrete is allowed to set unyielding to the touch of a finger. Concrete workers get on kneeboards to work areas where a power trowel machine cannot be operated. Working around plumbing pipe stubs, conduits, protruding rebars and other obstacles requires considerable time and effort.

Often, pen and paint elevation markings are removed and destroyed by the pouring of concrete. This requires a worker to use personal judgment other than an accurate means to level the concrete to the ascribed elevation.

Leveling to the ascribed elevation is particularly important because upward construction particularly stud walls are most prominent at perimeter locations as well as where plumbing pipes and conduits protrude through the floor. If the objectives of this step are not met, accurately, this is where trouble begins in the upward process of construction.

Often, because time is of the essence in completing a concrete pour the most critical areas of grade leveling around plumbing pipes, conduits and perimeters get neglected more than they should. Later a substantial amount of additional labor is required to rework these areas so upward construction can proceed in accord with the as intended building plan.

Thus, there remains a need for a floor height gauge for setting concrete floors that is faster than current methods, safe, easy to use and eliminates the need for excessive handwork and highly trained, skilled concrete workers to install a concrete floor to a proper uniform elevation.

SUMMARY OF THE INVENTION

In at aspect of, an elevation gauge system is provided that includes a plurality of gauges each having a tubular gauge body, a flange extending outward from one end of the gauge body, and a clamp for securing each of the gauges vertically to a protrusion placed through the tubular gauge body thereof.

In at least one embodiment, the clamp for securing each of the gauges to the protrusion comprises a threaded rod with a knob at one end that engages threads in the gauge body.

In at least one embodiment, at least one of the plurality of gauges has a cylindrical gauge body.

In at least one embodiment, at least one of the plurality of gauges has a square tube gauge body.

In at least one embodiment, the system includes a plurality of tubular stakes having an inner diameter for fitting the stakes over shear studs.

In at least one embodiment, the flange of each of the gauges has a notch therein extending inward from an outer perimeter of the flange.

In at least one embodiment, the notch extends inward non-radially.

In at least one embodiment, the gauge body has an outer surface and wherein the notch extends inwardly up to and not beyond the outer surface of the gauge body.

In at least one embodiment, at least one of the plurality of gauges has a square tube gauge body.

In at least one embodiment, the flange extends outward from the flange body up to about 1.5 inches.

Additional aspects of the present invention will be apparent in view of the description which follows.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of workers setting a concrete floor grade.

FIG. 2 is a perspective view of workers finishing critical floor grade areas.

FIG. 3 is a perspective view of a stud wall resting on critical floor grade areas.

FIG. 4 is a perspective view of workers setting a concrete floor grade with floor height gages.

FIG. 5 is a perspective and schematic view of floor height gauges in use.

FIG. 6 is a top perspective view of a floor height gauge.

FIG. 7 is a bottom perspective view of a floor height gauge.

FIG. 8 is a front elevation view of a floor height gauge.

FIG. 9 is a left side elevation view of a floor height gauge.

FIG. 10 is a top plan view of a floor height gauge.

FIG. 11 is a bottom plan view of a floor height gauge.

FIG. 12 is a second embodiment of a perspective view of workers setting a concrete floor grade with floor height gages.

FIG. 13 is a second embodiment of a perspective and schematic view of floor height gauges in use.

FIG. 14 is a top perspective view of a second embodiment of a floor height gauge.

FIG. 15 is a bottom perspective view of a second embodiment of a floor height gauge.

FIG. 16 is a front elevation view of a second embodiment of a floor height gauge.

FIG. 17 is a top perspective and schematic view of a sixth embodiment of a floor height gauge in use.

FIG. 18 is a top plan view of a second embodiment of a floor height gauge.

FIG. 19 is a bottom plan view of a second embodiment of a floor height gauge.

FIG. 20 is a top perspective view of a third embodiment of a floor height gauge.

FIG. 21 is a bottom perspective view of a third embodiment of a floor height gauge.

FIG. 22 is an elevation view of a floor height gauge in use with a screed.

FIG. 23 is an elevation view of a fourth embodiment of a floor height gauge in use on an upper floor.

FIG. 24 is a top perspective view of a fifth embodiment of a floor height gauge in an exploded view.

FIG. 25 is a top perspective view like FIG. 24 of a floor height gauge mounted on a pipe.

FIG. 26 is a top perspective view of a sixth embodiment of a floor height gauge.

FIG. 27 is a top perspective and schematic view of a sixth embodiment of a floor height gauge in use.

FIG. 28 is an elevation view of a sixth embodiment of a floor height gauge in use with a screed.

FIG. 29 is a top perspective and schematic view of a seventh embodiment of a floor height gauge in use.

FIG. 30 is a left side elevation view of FIG. 29.

FIG. 31 is a top plan view of FIG. 29.

FIG. 32 is a front elevation view of FIG. 29.

FIG. 33 is a back elevation view of FIG. 29.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 through FIG. 33 various aspects of the floor height gauge 56 and method of use to set a concrete slab 32 floor according to the present disclosure are described. It is to be understood, however, the examples are merely exemplary in describing the device and method of the present disclosure. Accordingly, any number of reasonable modifications, changes and substitutions are contemplated without departing from the spirit and scope of the present disclosure.

FIG. 1 is a perspective view of workers setting a concrete floor grade in a typical fashion. Concrete workers 46, in many instances, use a laser level 38 to set forms 36 on the ground 30 with the top of the form 36 being the slab top elevation 34. Many times, there are protrusions 44 such as plumbing pipe stubs, conduit and rebar that need to emerge from the concrete slab 32. Typically, a concrete worker will additionally mark the slab top elevation 34 on the protrusions 44 with a pen or paint elevation marking 42 to denote the slab top elevation 34.

FIG. 2 is a perspective view of workers 46 finishing critical floor grade areas. Concrete workers 46 continue throughout the pour to keep the reinforcing in the proper position and do finish work to keep the concrete slab 32 level, with hand tools 48, around protrusions 44, plumbing pipes and conduits protruding through the top of the established floor slab top elevation 34. Typically, after the concrete is screeded workers 46 bull float the concrete and add concrete in any low areas. Hand tools 48 or floats are used to work the edges of the slab to make sure the perimeter of the slab is flat and smooth, critical area around perimeters 52, as well as areas around where protrusions 44, plumbing pipes and conduits protrude through the floor, critical area around protrusions 50.

Often, pen and paint elevation markings 42 are removed and destroyed by the pouring of concrete. This requires a worker 46 to use personal judgment other than a scientifically accurate means to level the concrete to the ascribed slab top elevation 34.

FIG. 3 is a perspective view of a stud wall 54 resting on critical floor grade areas 50 and 52. Leveling to the ascribed slab top elevation 34 is particularly important because upward construction particularly stud walls 54 are most prominent at critical areas around perimeter 52 locations as well as critical area around protrusions 50 where plumbing pipes and conduits protrude through the floor. If the objectives of this step are not met, accurately, this is where trouble begins in the upward process of construction.

Often, because time is of the essence in completing a concrete pour the most critical areas 50 and 52 of grade leveling around plumbing pipes, conduits and perimeters get neglected more than they should. Later a substantial amount of additional labor is required to rework these areas so upward construction can proceed in accord with the as intended building plan.

FIG. 4 is a perspective view of workers 46 setting a slab top elevation 34 concrete floor grade with floor height gages 56 and FIG. 5 is a perspective and schematic view of floor height gauges 56 according to at least one embodiment in use.

Concrete workers 46 use a laser level 38, for example, to set forms 36 on the ground 30 with the top of the form 36 being the slab top elevation 34. Next a concrete worker 46 uses the protrusions 44 to his advantage by installing a floor height gauge 56, according to at least embodiment, by placing the gauge body 58 over the top of and around each protrusion 44. The gauge flange 60 may then be adjusted using a laser level 38, for example, to conform with the height of the slab top elevation 34 and which may be secured to the protrusion using knob or other means for securing the gauge to the protrusion 62. Although the use of a laser level is discussed herein, other tools for measuring the elevation may also be used.

A typical concrete slab 32 installation uses a multitude of floor height gauges 56 placed at a distance between 78 one another and the forms 36. The distance from ground 76 is about equal to the depth of the form 36 and the concrete slab 32.

Referring to FIG. 6 through FIG. 11 a floor height gauge 56 is described as having a tubular gauge body 58 formed as a surface around an open center such as a cylinder, square or any other geometric shape. The body 58 can be of any width or height to accommodate protrusions 44 which are made in a multitude of sizes and shapes. A gauge flange 60 is attached to or extends from the gauge body 58 and can be of any width or height to accommodate attachment to a gauge body 58, allowing a protrusion 44 to penetrate a gauge flange 60 at center. A gauge flange 60 may contain a notch 64. The purpose and size of a notch 64 is to accommodate the insertion of a string 66 of the kind typically used in construction for the establishing of construction lines. The knob type securing means 62 may include a threaded rod that inserts into a threaded connection in a gauge body 58 and has an knob end capable of rotationally turning the threaded rod through the wall of the gauge body 58 to make a positive connection with the end of the rod to the side of a protrusion 44. Thus, establishing a slab top elevation 34 by a concrete worker 46. A floor height gauge 58 can be made of metal, plastic or other composite materials. The securing means 62 may be a cam or other mechanism for clamping the gauge body 58 to the protrusions.

In at least one version of a first embodiment a gauge body 58 can measure about 3.5 inches across (e.g., diameter) by about 6 inches long (height). The gauge flange 60 can measure up to about 6.5 inches across (e.g., external diameter) and provide a surface of about 1.5 inches (measured from the gauge) to support the end of a screed 40.

FIG. 12 is a second embodiment of a perspective view of workers setting a concrete floor grade with floor height gages 56 and FIG. 13 is a second embodiment of a perspective and schematic view of floor height gauges 56 in use.

Concrete workers 46 use a laser level 38 to set forms 36 on the ground 30 with the top of the form 36 being the slab top elevation 34. Next a concrete worker 46 installs, by pushing a stake 68 into the ground 30, one or more floor height gauges 56 at locations proving to be valuable points of setting the slab top elevation 34, accurately, via use of a laser level 38. The gauge flange 60 is adjusted using a laser level 38 to conform with the height of the slab top elevation 34 and is secured in place by the use of a knob 62 about a stake 68.

Referring to FIG. 14 through FIG. 19 a floor height gauge 56 is described as having a tubular gauge body 58 formed as a surface around an open center such as a cylinder, square or any other geometric shape. The body 58 can be of any width or height to accommodate stake 68 which can be made in a multitude of sizes and shapes. A gauge flange 60 is attached to a gauge body 58 and can be of any width or height to accommodate attachment to a gauge body 58 allowing a stake 68 to penetrate a gauge flange 60 at center. A gauge flange 60 may contain a notch 64. In this embodiment, the notch 64 extends int the flange from the perimeter thereof non-radially. Moreover, the notch may extend inward up to and not beyond the outside surface of the gauge body 58, as shown in FIG. 18. This allows the string to be attached to a plurality of gauges without interference, as shown in FIG. 13. A square gauge body 58 further allows users to better set up square reference markers, as also shown in FIG. 13.

In at least one version of a second embodiment a stake 68 can measure about 1 inch in diameter by about 24 inches in length. A gauge body 58 can measure about 1.5 inches across (diameter or side of square) by about 4 inches long (height). The gauge flange 60 can measure about 5 inches across (outer diameter) and provide a surface of about 1.5 inches to support the end of a screed 40.

FIG. 20 is a top perspective view of a third embodiment of a floor height gauge 56 and FIG. 21 is a bottom perspective view of a third embodiment of a floor height gauge 56. FIG. 22 is an elevation view of a floor height gauge 56 in use with a screed 40. In the pouring of a concrete slab 32 a screed is a board, pipe or other long rigid object typically used to do a general leveling of the concrete to an established slab top elevation 34. A floor height gauge 56 securely fixed about a protrusion 44 or a stake 68 at the established slab top elevation 34 height, serves as a means to support one end of a screed 40 and allows one concrete worker 46 to rotate a screed 40 about a gauge body 58 to generally level the concrete to a top of slab elevation 34. This eliminate the need for a skilled worker to site the slab top elevation 34 and is a more scientific approach to keeping a concrete slab 32 more accurate in dimension and aid in upward construction accuracy.

FIG. 23 is an elevation view of a fourth embodiment of a floor height gauge in use on an upper floor. In this embodiment a stake 68 is a hollow tube of a diameter suitable to be positioned over a metal shear stud 70 such as is used in the construction of upper floors of a building, where steel floor deck 74 is supported by steel beams 72 and a concrete slab 32 is poured to a top slab elevation 34 on top of the steel floor deck 74.

FIG. 24 is a top perspective view of a fifth embodiment of a floor height gauge 56 in an exploded view and FIG. 25 is a top perspective view like FIG. 24 of a floor height gauge 56 mounted on a pipe protrusion 44. In this embodiment right and left hand gauge bodies 58 are made in an opposite interlocking configuration out of metal, plastic or composite material. Gauge body 58 radius dimensions can vary in conjunction with the outside diameter of standard pipe sizes or other protrusions 44 commonly found on domestic and commercial construction sites. Connection means 80 such as a zip tie, hook and loop strap or other means is used to secure gauge bodies 58 in place about protrusion 44. Gauge flange 60 is used as in other embodiments to provide about a 1.5 inch rest for measuring with laser level 38.

FIG. 26 is a top perspective view of a sixth embodiment of a floor height gauge 56, FIG. 27 is a top perspective and schematic view of a sixth embodiment of a floor height gauge 56 in use and FIG. 28 is an elevation view of a sixth embodiment of a floor height gauge 56 in use with a screed 40. In this embodiment a variation of a rest 82 is attached to a gauge body 58 to act as a means to support a horizontal member 84 such as an about 1.5 inch by about a 10 foot long pipe. A screed 40 can then be bridged between horizontal members 84 to level a concrete slab 32 to an appropriate slab top elevation 34.

Referring to FIG. 29 through FIG. 33 a seventh embodiment of a floor height gauge 56 in use. In this embodiment stake 68 is driven into the ground 30 to act as a secure member for adjustable support 86 to be slid over the top of stake 68 and secured at a designated elevation measured by a laser level 38 or other means. The adjustable support 86 is secured by an adjustment means 88 such as a threaded rod connected to a lever 90 enabling rotating of the adjustment means 88. A screed 40 is attached to a screed support 92 by fasteners 100 and placed over stake 68 to be supported by adjustable support 86. A worker 46 is able to rotate a screed 40 about stake 68 in a 360 degree circle eliminating the need of a worker to hold the opposite end of screed 40. Ground 30 or concrete 32 is able to be leveled to an elevation 34 by means of screed 40. Screed support 92 contains a hinge 94 enabling screed support 92 to articulate vertically in about a 30 degree angle plus or minus of horizontal. Thus providing a means for one worker 46 to screed 40 an angular grade as well as a horizontal grade.

While the foregoing invention has been described in some detail for purposes of clarity and understanding, it will be appreciated by one skilled in the art, from a reading of the disclosure, that various changes in form and detail can be made without departing from the true scope of the invention. 

What is claimed is:
 1. An elevation gauge system comprising a plurality of gauges each having a tubular gauge body, a flange extending outward from one end of the gauge body, and a clamp for securing each of the gauges vertically to a protrusion placed through the tubular gauge body thereof.
 2. The elevation gauge system of claim 1, wherein the clamp for securing each of the gauges to the protrusion comprises a threaded rod with a knob at one end that engages threads in the gauge body.
 3. The elevation gauge system of claim 1, wherein at least one of the plurality of gauges has a cylindrical gauge body.
 4. The elevation gauge system of claim 1, wherein at least one of the plurality of gauges has a square tube gauge body.
 5. The elevation gauge system of claim 1, comprising a plurality of tubular stakes having an inner diameter for fitting the stakes over shear studs.
 6. The elevation gauge system of claim 1, wherein the flange of each of the gauges has a notch therein extending inward from an outer perimeter of the flange.
 7. The elevation gauge system of claim 6, wherein the notch extends inward non-radially.
 8. The elevation gauge system of claim 7, wherein the gauge body has an outer surface and wherein the notch extends inwardly up to and not beyond the outer surface of the gauge body.
 9. The elevation gauge system of claim 8, wherein at least one of the plurality of gauges has a square tube gauge body.
 10. The elevation gauge system of claim 8, wherein the flange extends outward from the flange body up to about 1.5 inches. 